Brother PT-9200pc Service Manual

brother

SERVICE MANUAL
MODEL: PT-9200PC

IMM

LEW*©

brother.

SERVICE MANUAL

MODEL: PT-9200PC

© Copyright Brother 1998

All rights reserved.

No part of this publication may be reproduced in any
form or by any means without permission in writing from
the publisher.

Specifications are subject to change without notice.

PREFACE

This publication is a service manual covering the specifications, theory of operation,

disassembly/

reassembly procedure, and troubleshooting of the Brother label printer PT-9200PC. It is

intended for service personnel and other concerned persons to accurately and quickly provide

after-sale service for our PT-9200PC.

To perform appropriate maintenance so that the machine is always in best condition for the
customer, the service personnel must adequately understand and apply this manual.

This manual is made up of four chapters and an appendix.

CHAPTER I
CHAPTER II
CHAPTER III
CHAPTER IV
APPENDIX

SPECIFICATIONS
MECHANISMS
ELECTRONICS
TROUBLESHOOTING
CIRCUIT DIAGRAM

CHAPTER I

SPECIFICATIONS

CONTENTS

CHAPTER I SPECIFICATIONS

1.1 MECHANICAL SPECIFICATIONS 1-1

.1.1 External View 1-1

.1.2 Input Specifications I-2

.1.3 Display Specifications I-2

.1.4 Printing Specifications I-2

.1.5 Tape Cassette Specifications I-3

.1.6 Tape Cutter Specifications I-3

.1.7 PC Interface Specifications I-3

1.2 ELECTRONIC SPECIFICATIONS I-4

1.2.1 Power Supply Specifications I-4

1.1 MECHANICAL SPECIFICATIONS

1.1.1 External View

(1 ) Dimensions (W x D x H)

(2) Weight

Machine proper
Machine and package

1 1 5 mm x 245 mm x 1 45 mm

Approx. 1 .5 kgf (only the machine)
Approx. 2.4 kgf

145 mm

115 mm

245 mm

Fig. 1.1-1 External View

I- 1

1 .1 .2 Input Specifications

(1) Number of keys

(2) Key layout

2 (ON/OFF (6) and FEED/CUT (X) keys)
See Fig. 1.1-2.

FEED/CUT key

ON/OFF key

Fig. 1.1-2 Key Layout

1 .1 .3 Display Specifications

(1) Display method

1.1.4 Printing Specifications

(1) Printing method

(2) Printing speed

(3) Print head

Type

Dimensions of a heating
element

LED (green/red)

Thermal transfer or heat sensitizing method
by thermal head

Printing on plastic tapes (laminated and non-
laminated tapes) or special tapes (instant
lettering tape, non-laminated thermal film
tape, and fabric printing tape)
(Fixed print head and tape feed mechanism)

20 mm/sec

Thin film thermal head
384 dots x 1 dot

0.08 mm wide by 0.0545 mm high

I-2

1 .1 .5 Tape Cassette Specifications

(1) Cassette

(2) Types of cassettes

Laminated tape cassette

Non-laminated tape

cassette

Instant lettering tape

cassette

Fabric printing tape

cassette

Stamp tape cassette

(3) Tape size

Cartridge type

Laminated tape, ink ribbon, and adhesive
base tape

Non-laminated tape and ink ribbon

Instant lettering tape and ink ribbon

Fabric printing tape and ink ribbon
Porous-stamp tape and mount

Width

Length

Laminated tape

6,9,12,18,24,36 mm

8 m

(5 m for fluorescent

coating tapes)

Non-laminated tape

6,9,12,18,24 mm

8 m

Instant lettering tape

18 mm

8 m

Fabric printing tape

18 mm

8 m

Stamp tape

18 mm

8 m

1 .1 .6 Tape Cutter Specifications

(1) Tape cutting method

Automatic full cutting method
(not user-replaceable)

Automatic half cutting method
(not user-replaceable)

1 .1 .7 PC Interface Specifications

(1) Method

Serial (RS-232C)
Baud rate

(2) Attachments

l/F cable
Editor

Max. 115.2 K

Dedicated cable
Dedicated editor

I-3

1 .2 ELECTRONIC SPECIFICATIONS

1 .2.1 Power Supply Specifications

(1 ) Power supply method

Commercially available power (120V AC, 60 Hz for North America, and 230V
AC, 50 Hz for Europe) is input and stabilized to generate DC voltage by the
switching regulator in the machine.

The power supply cord is inserted into an inlet.

I-4

CHAPTER II

MECHANISMS

CONTENTS PT99007

CHAPTER II MECHANISMS

2.1 THEORY OF MECHANISM OPERATION 11-1

2.1.1 Printing Mechanism 11-1

2.1 .2 Roller Holder Assy Setting and Retracting Mechanism II-3

2.1.3 RegularTape and Ribbon Feed Mechanism II-4

2.1.4 Tape Automatic Full Cutter Mechanism II-6

2.1.5 Tape Automatic Half Cutter Mechanism II-7

2.1.6 Forced Tape Eject Mechanism II-8

2.1.7 Cover Open Button (Cover Lock Button) II-9

2.1.8 Cover Open (Cover Lock) Sensor II-9

2.2 DISASSEMBLY AND REASSEMBLY 11-10

2.2.1 Disassembly Procedures 11-11

[I] Removing the Tape Cassette 11-11

[2] Removing the Cassette Cover 11-11

[3] Disassembly of the Cassette Cover Components 11-12

[4] Removing the Lower Cover 11-13

[5] Removing the Bottom Cover and the Front Cover 11-14

[6] Removing the Power Supply PCB Assy 11-16

[7] Removing the Main PCB Assy and the Mechanical Printing Unit 11-18

[8] Disassembly of the Body Cover II-20

[9] Removing the Eject Unit Assy, the Half Cutter Assy, the Half Spacer,

and the Cutter Assy II-23

[10] Removing the Half Frame Assy II-24

[II] Disassembly of the Mechanical Unit II-26

[12] Disassembly of the Head/Roller Holder Unit II-28

2.2.2 Reassembly Procedures II-29

[I] Reassembly of the Head/Roller Holder Unit II-29

[2] Reassembly of the Mechanical Unit II-30

[3] Reassembly of the Half Frame Assy II-32

[4] Reassembly of the Cutter Assy, the Half Spacer, the Half Cutter Assy,

and the Eject Unit Assy II-34

[5] Reassembly of the Body Cover II-35

[6] Reassembly of the Mechanical Printing Unit and the Main PCB assy II-38

[7] Reassembly of the Power Supply PCB Assy 11-41

[8] Reassembly of the Covers II-44

[9] Reassembly of the Cassette Cover Components II-47

[10] Reassembly of the Cassette Cover II-48

[II] Reassembly of the Tape Cassette II-48

[12] Test Printing and Operation Check II-49

2.1 THEORY OF MECHANISM OPERATION

2.1.1 Printing Mechanism

(1 ) Construction of thermal head

This machine uses thermal transfer printing. The thermal head contains 384
heating elements vertically arranged. The size of one heating element is
0.08 mm wide by 0.0705 mm (pitch) high, as shown in Fig. 2.1-1.

0.0705 mm (1/360")

27.056 mm

0.08 mm

Fig. 2.1-1 Heating Elements of the Thermal Head

(2) Theory of printing

During printing operation, the cylindrical rubber platen crimps the tape* and the
ink ribbon** on the thermal head. At this time, the CPU selects the required
heating elements out of the 384 heating elements to energize them. The
theory of printing depends on the use of non-laminated thermal film tape
cassettes or other tape cassettes:

(*) Laminated tape when using laminated tape cassettes.

Non-laminated tape when using non-laminated tape cassettes.
Instant lettering tape when using instant lettering tape cassettes.
Fabric printing tape when using fabric printing tape cassettes.
Stamp tape when using stamp tape cassettes.

(**) When using non-laminated thermal film tape cassettes, no ink ribbon is
present.

[For non-laminated thermal film tape cassettes]

If the selected heating element(s) generates heat, the thermal film tape
develops itself to produce a dot on the tape. The tape is advanced and the
next printing cycle is repeated, thus forming a character and graphics on the
tape.

When using laminated tape cassettes, instant lettering tape cassettes, or fabric
printing tape cassettes, print data is processed so that a character and
graphics read correctly when viewed from the opposite side of the printing
surface of the tape. (In other words, the mirror image of the character and
graphics is printed.)

[For stamp tape cassettes]

If the selected heating element(s) generates heat, the porous-stamp tape will
be melted so that a pore(s) will be formed in the tape. The tape is advanced
and the next heating cycle is repeated, thus forming a character of pores in the
tape. The printed stamp tape can be used as the face of a stamp. When the
stamp is pressed against the ink-pad, it will absorb ink through the pores.

(3) Character Formation

While the main motor (stepping motor) feeds the tape and ink ribbon (tape only
when using non-laminated thermal film tape cassettes or stamp tape
cassettes) by 0.0705 mm for 3.5 ms, the thermal head generates heat once.
The feed amount of 0.0705 mm is smaller than the width (0.08 mm) of the
heating elements so that the heat generated at one heating cycle will overlap
with the next heating cycle. This forms a character having no gap between
adjacent printed dots.

2.1.2 Roller Holder Assy Setting and Retracting Mechanism

This mechanism consists of the release cam, roller release rod, and roller
holder/head assy.

The roller holder assy incorporates the platen holder and the sub roller holder.
These holders support the platen and the tape feed sub roller so that they can
move perpendicularly to the thermal head and the tape feed roller, respectively.

The platen is pressed perpendicularly against the thermal head under a uniform
load regardless of the thickness of the tape, so that the tape is fed.

Closing the cassette cover pushes down the release cam which moves the roller
release rod to the left (when viewed from the front of the machine). This pivots the
roller holder assy around the shaft secured on the thermal head assy so as to press
the roller holder assy against the thermal head.

The platen is pressed perpendicularly against the thermal head with the tape and
ink ribbon (only the tape when using non-laminated thermal film tape cassettes or
stamp tape cassettes) sandwiched inbetween under a uniform load by the platen
spring.

At the same time, the platen gear becomes engaged with the platen idle gear.

Also, the tape feed sub roller is pressed perpendicularly against the tape feed roller
built in the tape cassette with the tape (and base paper when using laminated tape
cassettes or stamp tape cassettes) sandwiched inbetween under a uniform load by
the sub roller holder springs. At the same time, the sub roller gear becomes
engaged with the tape feed gear.

Opening the cassette cover causes the release lever spring to slide the roller
release rod in the direction of the arrow. This retracts the roller holder assy from the
thermal head, providing you with enough space to replace the tape cassette.

Adhesive base tape
Platen idle gear

Tape feed roller
Platen roller

Tape feed sub roller

Tape cassette

Laminated tape

Ink ribbon

Release cam
Roller holder assy ^ Roller holder shaft

Roller release rod Thermal head assy

Platen gear Platen roller

Sub roller gear

Sub roller

Roller holder

Platen spring
Sub roller spring

Fig. 2.1-2 Roller Holder Assy Setting and Retracting Mechanism

II -3

2.1.3 Regular Tape and Ribbon Feed Mechanism

This mechanism consists of the tape feed motor, the gear train, and the roller holder
assy.

(1) Regular Tape Feeding

When you load a tape cassette and close the cassette cover, the platen and
the thermal head sandwich the tape and ink ribbon (only the tape when using
non-laminated thermal film tape cassettes or stamp tape cassettes) inbetween.
Also, the tape feed sub roller in the roller holder assy and the tape feed roller
inside the tape cassette sandwich the tape (and base paper when using
laminated tape cassettes or stamp tape cassettes) inbetween, as described in
Subsection 2.1.2.

As the tape feed motor (stepping motor) rotates, the rotation is transmitted via
the gear train to the platen idle gear (which rotates the platen gear) and the
tape feed gear (which rotates the tape feed roller and the tape feed sub roller
at the same rotation speed).

Accordingly, the sandwiched tape and ink ribbon will be advanced. (When a
laminated tape cassette is mounted, the sandwiched laminated tape, adhesive
base tape, and ink ribbon will be advanced together.)

The feeding amount of the tape feed sub roller is slightly greater than that of
the platen roller.

Adhesive base tape

Tape feed roller
Platen idle gear

Tape feed sub roller

Platen roller

Transparent laminated tape

Thermal head assy
Roller holder assy

Main frame

Tape feed gear
Sub roller gear

Tape feed motor
Platen idle gear

Platen gear
Fig. 2.1-3 Tape Feed Mechanism

(2) Adhesive Base Tape Feeding (only for laminated tape cassettes)

A laminated tape cassette contains both a transparent laminated tape roll and
a separate adhesive base tape roll.

When a transparent laminated tape and an adhesive base tape pass through
the contact point (between the tape feed roller and tape feed sub roller), they
are then bonded together into a single, printed tape. The ink printed on the
laminated tape is, therefore, sealed up with the adhesive base tape.

(3) Ink Ribbon Feeding (except for non-laminated thermal film tape cassettes and
stamp tape cassettes)

As the main motor rotates, the ribbon drive cam located at the middle of the
gear train rotates counterclockwise. When fitted on the ribbon drive cam, the
ribbon take-up roll in the tape cassette also rotates to take up the ink ribbon.

To apply proper tension to the ink ribbon between the platen roller and the
ribbon drive cam, the feed amount of the ribbon drive cam is slightly greater
than that of the tape feed gear. The difference between the feed speeds at
the platen roller and at the ribbon drive cam is absorbed by the clutch spring
which is integrated in the ribbon drive cam and allows the cam to slip.

This way, the ink ribbon is kept tense, which enables the ribbon to clearly
separate from the tape at the stabilized angle after printing.

Tape feed roller

Tape feed sub roller

Ribbon take-up roll

Ink ribbon

Platen roller \ Thermal head assy

Roller holder assy

Main frame

Ribbon drive cam

Tape feed motor

Fig. 2.1-4 Ribbon Feed Mechanism

2.1.4 Tape Automatic Full Cutter Mechanism

The tape automatic full cutter mechanism consists of a stationary blade and a
movable blade driven by the full cutter motor.

Upon completion of printing and tape feeding, the CPU activates the full cutter
motor (DC motor) whose clockwise rotation is transmitted to the cutter helical gear.

As the cutter helical gear rotates counterclockwise, its boss "A" (which is fitted in the
opening of the movable blade) actuates the movable blade to pivot it around shaft
"B". Consequently, the cutter cuts the printed tape routing through the movable and
stationary blades, just like a pair of scissors.

Subsequently, the CPU keeps the full cutter motor on. When the movable blade
returns to the home position, part "C" of the cutter helical gear presses the full cutter
sensor switch secured on the half frame. The moment the CPU receives the sensor
signal, it stops the full cutter motor.

Stationary blade

Full cutter sensor

Movable blade
Full cutter motor assy

A Cutter helical gear

Cutter helical gear
Fig. 2.1-5 Tape Automatic Full Cutter Mechanism

II -6

2.1.5 Tape Automatic Half Cutter Mechanism

The tape automatic half cutter mechanism consists of a stationary plate and a half
cutter holder (equipped with a cutter blade) which is operated by the half cutter
motor.

Half cutting is performed only for laminated tapes.

Upon completion of printing and tape feeding, the CPU activates the half cutter
motor (DC motor) whose counterclockwise rotation is transmitted to the half rock
gear by the clutch gear and the three idle gears.

As the half rock gear rotates counterclockwise, its groove "D" (into which the
projection on the half cutter holder is inserted) operates the half cutter holder to
pivot it around shaft "E". The stationary plate is provided with space as wide as the
separator of a laminated tape. A laminated tape is pressed against the stationary
plate by the half cutter holder for half cutting.

Half cutting refers to cutting a tape except its separator.

Subsequently, the CPU rotates the half cutter motor counterclockwise to return the
half cutter holder to the home position. Part "F" of the half rock gear presses the
half cutter sensor switch provided on the half frame. The moment the CPU receives
the sensor signal, it stops the half cutter motor.

Stationary blade

Half cutter motor assy
- P "D"

Half cutter holder

Half rock gear
Half cutter sensor

Separator

Tape

Cut line

Fig. 2.1-6 Tape Automatic Half Cutter Mechanism

2.1.6 Forced Tape Eject Mechanism

The forced tape eject mechanism consists of the stationary roller unit and the eject
roller unit interlocked with the cutter mechanism.

Upon completion of printing and tape feeding to operate the cutter mechanism, the
cutter helical gear rotates counterclockwise, as described in Subsection 2.1.4.
Projection "A" (which is fitted on cam "G" of the eject roller unit) operates the eject
roller unit to pivot it around shaft "H". Immediately before the cutter starts cutting
the printed tape, the tape is pressed against the stationary roller by the eject roller
and held in place until the cutter completes cutting the tape. These operations of
the cutter and the eject roller unit are controlled by cam "G".

Upon completion of the cutting of the tape by the cutter, released cam "G" causes
the spring to slide the eject roller unit in direction "J". At this time, the two cams and
springs below the eject roller rotate the eject roller in direction "K" to eject the tape
that has been held in place.

Subsequently, the eject roller unit stops at stopper "L" of the stationary roller unit.

Stationary roller unit

Cutter helical gear

Fig. 2.1-7 Forced Tape Eject Mechanism

II -8

2.1.7 Cover Open Button (Cover Lock Button)

Pressing the cover open button (cover lock button) slides the cover button actuator
to the left. This presses the cover lock actuator of the cassette cover, releasing the
hook to open the cassette cover.

Cover lock actuator

Cover open button
(Cover lock button)

Cover button actuator

Fig. 2.1-8 Cover Open Button

2.1.8 Cover Open (Cover Lock) Sensor

The cover open (cover lock) sensor (push switch) is provided on the cassette
sensor PCB. Closing the cassette cover puts its sensor tab on the cover open
(cover lock) sensor (push switch), signaling that the cassette cover is closed.

Cassette cover

Cover open switch
(push switch)

Cassette sensor PCB

Fig. 2.1-9 Cover Open Sensor

II -9

2.2 DISASSEMBLY AND REASSEMBLY

Precautions on Safety

PT99007

(1) Disassemble and reassemble the machine on a grounded antistatic sheet.
Touching electronic components such as an LSI with an electrified hand will
break them, as they are easily affected by static electricity.

(2) Wrap the machine in an electrically conductive aluminum sheet before carrying
it.

(3) When using heating tools such as soldering iron, take care not to thermally
break resin components such as a wire, a PCB, and a cover.

(4) Take care not to lose small components, such as a screw and a washer, which
have been removed to replace other components.

(5) Tighten screws according to the list of tightening torque below.
List of Tightening Torque

Position

Screw

Qty.

Tightening torque [kgf-cm]

Head/roller holder unit

Screw, pan (S/P washer) M3x10

2

59±10 N-cm (6±1 kgf-cm)

Eject unit

Screw, pan (S/P washer) M4x12

2

88±10 N-cm (9±1 kgf-cm)

Half frame

Screw, pan (S/P washer) M3x6

2

59±10 N-cm (6±1 kgf-cm)

Tape feed motor

Screw, pan M2.6x3.5

2

39±10 N-cm (4±1 kgf-cm)

Full cutter motor

2

Half cutter motor

2

Full cutter sensor

Screw, pan M 1.7x6

1

15±5 N-cm (1.5±0.5 kgf-cm)

Half cutter sensor

1

Main frame

Taptite, bind B M2.6x8

2

39±10 N-cm (4±1 kgf-cm)

Tape end sensor

2

Main PCB

3

Cassette cover bracket

2

Sub PCB

2

Inlet bracket

2

Power supply PCB

2

Bottom cover

Taptite, bind B M2.6x10

3

39±10 N-cm (4±1 kgf-cm)

Lower cover

1

Inlet

Screw, flat B M3x10

2

39±10 N-cm (4±1 kgf-cm)

Shield plate B

Screw, pan (S/P washer) M4x8

1

59±10 N-cm (6±1 kgf-cm)

Ground wire

1

II- 10

2.2.1 Disassembly Procedures

[1] Removing the Tape Cassette

(1 ) Pressing the cover open button (cover lock button) releases the hook to
open the cassette cover.

(2) Opening the cassette cover releases the platen from the thermal head
simultaneously. Hold both sides of the tape cassette and lift it to remove
it.

Tape cassette

Cover open button
(Cover lock button)

Cassette cover

Front cover

Fig. 2.2-1 Removing the Tape Cassette
<Disassembly of the Covers>

[2] Removing the Cassette Cover

While pressing part "A" with the end of a screwdriver, slightly tilt the cassette
cover with side "B" turned upwards, and lift the cassette cover to remove it.

Part "A :

Cassette cover

Fig. 2.2-2 Removing the Cassette Cover

11-11

[3] Disassembly of the Cassette Cover Components

(1 ) Release each of the three hooks of the cassette cover securing the
cassette presser with the end of a screwdriver to remove the cassette
presser. Removing the cassette presser removes the cassette spring.

Cassette presser

Cassette spring

Cassette cover

Hooks

Fig. 2.2-3 Removing the Cassette Presser and Spring

(2) Release the hooks on both sides of the cover lock actuator with the end of
a screwdriver to remove the cover lock actuator. Removing the cover lock
actuator removes the cover lock spring.

Cover lock actuator

Cassette cover

Fig. 2.2-4 Removing the Cover Lock Actuator and Spring

11-12

[4] Removing the Lower Cover

Turn the machine over, and remove the screw from the lower cover to remove
the lower cover.

Screw

Lower cover

Bottom cover

Fig. 2.2-5 Removing the Lower Cover

11-13

[5] Removing the Bottom Cover and the Front Cover

(1 ) Remove screws "A" and "B" securing the ground wire.

Screw "A"
Screw "B"

round wire

Shield plate B

Half frame

Fig. 2.2-6 Removing the Screws Securing the Ground Wire

(2) Remove screws "C" and "D" securing the bottom cover.

Then, remove the core of the inlet bracket unit from the storage space in
the bottom cover, before removing screw "E" securing the bottom cover.

Core

Screw

Screw "E"

Bottom cover

Bottom cover

Fig. 2.2-7 Removing the Screws Securing the Bottom Cover

11-14

(3) While pressing the body cover, lift both sides of the bottom cover to
remove it.

(4) Pull out the power supply harness and connector from the main PCB.
Caution: Do not pull the harness; hold the connector to pull it out.

Bottom cover

Power supply harness

Main PCB

Fig. 2.2-8 Removing the Power Supply Harness and Connector

(5) While pressing the body cover, lift the front cover diagonally to remove it.

Main PCB

Body cover

Front cover

Fig. 2.2-9 Removing the Front Cover

11-15

[6] Removing the Power Supply PCB Assy

(1 ) Remove the two screws securing the inlet bracket.

(2) Turn the bottom cover over and remove the inlet unit.

Two screws

Bottom cover

Inlet unit

Fig. 2.2-10 Removing the Inlet Unit

(3) Remove the two screws securing the power supply PCB assy.

(4) Release the power supply harness from the hook of the bottom cover, and
lift the power supply PCB assy to remove it.

(5) Lift shield plate B to remove it.

Two screws

Bottom cover

Power supply PCB assy

Shield plate B

Fig. 2.2-11 Removing the Power Supply PCB Assy and Shield Plate B

11-16

(6) Remove the two screws securing the inlet assy to remove the inlet assy
from the inlet bracket.

Inlet bracket

nlet assy

Two screws

Fig. 2.2-12 Removing the Inlet Assy

(7) Remove the inlet assy and power supply harnesses from the power supply
PCB assy.

Power supply harness

Inlet assy harness

Power supply PCB assy

Fig. 2.2-13 Removing the Inlet Assy and Power Supply Harnesses

11-17

[7] Removing the Main PCB Assy and the Mechanical Printing Unit

(1 ) Unplug the following connectors and cables.

Caution 1: Be sure to unlock the connector before removing the head

flexible cable.
Caution 2: Take care not to damage the connectors and cables.

Half cutter sensor connector (P8)

Sensor PCB harness (P3)
Sub PCB harness (P2)

Head flexible cable (P9)

Full cutter sensor connector (P7)
Tape feed motor connector (P10)

Body cover

Connector to be unlocked

Main PCB assy

Fig. 2.2-14 Removing the Connectors and Cables

11-18

(2) Remove the three screws securing the main PCB, and lift the top of the
main PCB assy to remove it.

Mechanical printing unit

Three screws

Main PCB assy

Shield plate A

Body cover

Fig. 2.2-15 Removing the Main PCB Assy

(3) Remove the two screws securing shield plate A and the mechanical
printing unit to remove them.

Two screws

Mechanical printing unit

Shield plate A

Body cover

Fig. 2.2-16 Removing the Mechanical Printing Unit

11-19

[8] Disassembly of the Body Cover

(1 ) Remove the two screws from the cassette cover bracket, and lift the
cassette cover bracket to remove it.

Body cover

Cassette cover bracket

Fig. 2.2-17 Removing the Cassette Cover Bracket

(2) Rotate the cover open cam in direction "A" until it stops and then remove it.

Cover open cam

Cassette cover bracket

Fig. 2.2-18 Removing the Cover Open Cam

II -20

(3) Remove the damper rubber from the cassette cover bracket, and release
the hook of the cover open cam to remove the cover open spring.

Cassette cover bracket

Damper rubber

Cover open cam

Cover open spring

Fig. 2.2-19 Removing the Damper Rubber and the Cover Open Spring

(4) Remove the two screws to remove the tape end sensor assy.

(5) Release the two hooks of the body cover to the outside of the sensor PCB
to remove the sensor PCB assy.

Two screws
Body cover

Tape end sensor assy

Hook

Sensor PCB assy

Hook

Fig. 2.2-20 Removing the Tape End Sensor Assy and the Sensor PCB Assy

11-21

(6) Remove the two screws to remove the sub PCB assy.

(7) Press the cut feed button, the power supply actuator, and the power
supply switch button secured on the sub PCB assy from the front of the
body cover to remove them.

Remove the power supply switch button from the power supply actuator.

Two screws

Power supply switch button
(ON/OFF key)

Body cover

Power supply actuator

Cut feed button
(FEED/CUT key)

Fig. 2.2-21 Removing the Sub PCB Assy and the Button

(8) Release the two hooks on the back of the cover lock button to remove the
cover lock button from the body cover.

(9) Remove the cover lock spring.

Hooks

Body cover

Cover lock spring

Cover lock button

Fig. 2.2-22 Removing the Cover Lock Button and Spring

II -22

(10) Press the resin spring on the back of the cover lock actuator to remove the
cover lock actuator from the body cover.

Body cover

Resin spring on the back of the
cover lock actuator

Cover lock actuator

Body cover

Fig. 2.2-23 Removing the Cover Lock Actuator
<Disassembly of the Mechanical Printing Unit>

[9] Removing the Eject Unit Assy, the Half Cutter Assy, the Half Spacer,
and the Cutter Assy

Remove the two screws on the side of the mechanical unit to remove the eject
unit assy, the half cutter assy, the half spacer, and the cutter assy.

Warning: Take care not to be injured by the blades of the cutter assy and the
half cutter assy.

Cutter assy
(Full cutter assy)

Half spacer

Mechanical unit

Two screws

Eject unit assy

Fig. 2.2-24 Removing the Eject Unit Assy, the Half Cutter Assy,
the Half Spacer, and the Cutter Assy

II -23

[10] Removing the Half Frame Assy

(1 ) Remove the half rock gear.

(2) Remove the retaining ring from the cutter helical gear to remove the cutter
helical gear.

Half frame assy

Half rock gear

Cutter helical gear
Retaining ring

Fig. 2.2-25 Removing the Half Rock Gear and the Cutter Helical Gear

(3) Remove the two screws to remove the half cutter sensor assy and the full
cutter sensor assy.

Half frame assy

Full cutter sensor assy
Screws

Main frame

Half cutter sensor assy

Fig. 2.2-26 Removing the Half Cutter Sensor Assy and the Full Cutter Sensor Assy

II -24

(4) Remove the two screws to remove the half cutter motor assy.

(5) Remove the two screws from the full cutter motor assy, and pull the full
cutter motor assy backward to remove it. At this time, take care not to
damage the motor worm gear.

Half cutter motor assy

Two screws

Two screws

Half frame assy

Full cutter motor assy

Fig. 2.2-27 Removing the Half Cutter Motor Assy and the Full Cutter Motor Assy

(6) Remove the two screws from the half frame assy to remove it.

Two screws

Half frame assy

Main frame

Fig. 2.2-28 Removing the Half Frame Assy

11-25

[1 1] Disassembly of the Mechanical Unit

(1 ) Remove the two screws from the back of the tape feed motor to remove
the tape feed motor assy.

Two screws

Tape feed motor assy

Main frame

Fig. 2.2-29 Removing the Tape Feed Motor Assy

(2) Remove the two screws and press the back of the head/roller holder unit
to remove it. At this time, detach the tape securing the thermal head cable
on the frame assy.

Two screws

Head/roller holder unit

Securing tape Thermal head cable

Main frame

Fig. 2.2-30 Removing the Head/Roller Holder Unit

II -26

(3) Pull the release lever spring slightly to remove it.

(4) After removing the retaining ring, remove the roller release rod while tilting
it in direction "A".

(5) Pull the release cam out of the shaft.

(6) As the release rod roller is secured in place by the elasticity of the resin of
the roller release rod, press the shaft of the release rod roller to remove it
from the roller release rod.

Roller release rod

Main frame

Release cam

Release rod roller

Release lever spring
Roller release rod

Main frame

Fig. 2.2-31 Removing the Roller Release Rod

II -27

[12] Disassembly of the Head/Roller Holder Unit

PT99007

(1) Remove the retaining ring from the top of the head assy, and pull the roller
holder shaft downward to remove it.

(2) While tilting the bottom of the roller holder assy toward you, remove the
roller holder assy from the head assy.

Note: Do not touch the rubber platen. Touching the platen may impair
printing quality.

Retaining ring

Head assy

Platen (rubber)

Roller holder assy

Roller holder shaft

Fig. 2.2-32 Removing the Roller Holder Assy

(3) Remove the roller holder release spring.

Note: Take care not to lose the roller holder release spring which is

removed simultaneously when the roller holder assy is removed.

Roller holder release spring

Roller holder assy

Fig. 2.2-33 Removing the Roller Holder Release Spring

II -28

2.2.2 Reassembly Procedures

[1] Reassembly of the Head/Roller Holder Unit

PT99007

(1 ) Apply the specified grease (1 mm 3 ) on each of the top and bottom of the
platen shaft of the roller holder assy. (Specified grease: Silicone grease
G501)

Top of the platen shaft

Roller holder assy

Bottom of the platen shaft

Fig. 2.2-34 Applying the Grease on the Platen Shaft

(2) Set the roller holder release spring at the bottom of the shaft of the roller
holder assy. With one of the hooks of the roller holder release spring
inserted into the groove in the roller holder, insert the platen shaft at the
top of the roller holder assy, into the slit at the top of the head assy, while
tilting the roller holder assy.

Then, insert the shaft at the bottom into the slit at the bottom of the head
assy to set the roller holder assy.

At this time, check that the release spring is hooked on the correct portion
of the head assy.

(3) After inserting the roller holder shaft from the bottom of the head assy, set
the retaining ring at the top of the shaft.

At this state, check that the roller holder rotates smoothly by pressing the
back of the roller holder assy.

Head assy

.Retaining ring

Roller holder assy

Roller holder shaft

Roller holder release spring

Fig. 2.2-35 Reassembly of the Roller Holder Assy

-29

[2] Reassembly of the Mechanical Unit PT99007

(1 ) Set the release rod roller by inserting it into the slit in the roller release rod.

(2) Set the release cam on the release lever guide shaft.

(3) While tilting the roller release rod, set it on the release cam shaft and the
projection on the release cam, and then on the release lever guide shaft.

(4) Set the retaining ring on the release lever guide shaft.

(5) After hooking the release lever spring on the hole at the bottom of the
roller release rod, pull the release lever spring to hook it on the hole in the
frame.

(6) Apply the specified grease (3 mm 3 ) on each of the inside of the square
hole in the roller release rod and the release rod roller. (Specified grease:
Silicone grease G501)

Release cam shaft Release cam

. Roller release rod

, Apply the grease here.

a"

„ , \ . Retaining

Release lever a

guide shaft

Release rod roller

Apply the grease here.

Main frame

Release lever spring
Roller release rod

Projection

Release lever spring

Main frame

Fig. 2.2-36 Reassembly of the Roller Release Rod

II -30

PT99007

(7) After passing the harness through the oblong hole in the frame and setting
the head/roller holder unit on the boss and the hole in the frame, tighten the
two screws.

(8) Check that the roller holder rotates smoothly by moving the release cam
vertically.

Two screws

Head/roller holder unit

Head assy

Oblong hole in the
main frame

Boss on the main frame

Main frame

Fig. 2.2-37 Reassembly of the Head/Roller Holder Unit

(9) Set the tape feed motor assy on the frame, and tighten the screws from the
back of the frame.

Note: Backlash on the motor gear should be 0.05 to 0.3 mm.

Main frame

Two screws

Tape feed motor assy

Fig. 2.2-38 Reassembly of the Tape Feed Motor Assy

11-31

[3] Reassembly of the Half Frame Assy

PT99007

(1 ) With the holes in the frame set on the bosses on the half frame assy,
tighten the two screws from the half frame side.

Two screws

Half frame assy

Boss on the half frame

Boss on the half frame

Main frame

Fig. 2.2-39 Reassembly of the Half Frame Assy

(2) After applying the specified grease (2 mm 3 ) on the end of the motor worm
gear, insert the full cutter motor assy into the square hole in the half frame
assy from the back then insert the end of the motor worm gear into the
small hole in the half frame. After that tighten the two screws with the end
of the motor worm gear pressed downward. (Specified grease: Silicone
grease G501)

(3) Insert the half cutter motor assy from the back of the half frame assy, and
tighten the two screws. Then, apply the specified grease (3 mm 3 ) on the
gear of the half cutter motor assy. (Specified grease: Silicone grease
G501)

Backlash on the motor gear should be 0.05 to 0.3 mm.

Half cutter motor assy

Apply the grease here.

Two screws

Apply the grease here.

Two screws

Half frame assy

Full cutter motor assy

Fig. 2.2-40 Reassembly of the Half Cutter Motor Assy and the Full Cutter Motor Assy

-32

PT99007

(4) After setting the half cutter sensor assy and the full cutter sensor assy in
place, tighten the screw for each of them.

Check that the projections on the sensors are inserted into the holes in the
half frame.

Note: Observe the colors of their harnesses (half cutter sensor harness:
black, full cutter sensor harness: blue).

Half frame

Full cutter senso

Screw

Mechanical unit

Projection
Half cutter sensor assy

Screw
Projection

Fig. 2.2-41 Reassembly of the Half Cutter Sensor Assy and the Full Cutter Sensor Assy

(5) Mount the cutter helical gear onto the shaft and check to be sure that the
backlash between the helical gear and the cutter worm gear is to 0.1 mm.
If the backlash is greater than this range, remove the two screws of the full
cutter motor and adjust the backlash correctly. After obtaining the correct
amount of backlash, set the retaining ring on the shaft.

(6) Set the half rock gear with its groove tilted at an approximately 45° angle.
Then, apply the specified grease (3 mm 3 ) on the inside of the groove.
(Specified grease: Silicone grease G501)

Half frame assy

Apply the grease here.

Cutter helical gear
Retaining ring

Fig. 2.2-42 Reassembly of the Cutter Helical Gear and the Half Rock Gear

II -33

PT99007

[4] Reassembly of the Cutter Assy, the Half Spacer, the Half Cutter Assy,
and the Eject Unit Assy

(1 ) Apply the specified grease (3 mm 3 ) on each slot of the cams in the cutter
assy and the eject unit assy, where the cutter rock pin slides up and down.
(Specified grease: Silicone grease G501)

(2) After inserting the cutter rock pin into the groove in the movable blade of the
cutter assy, insert the two locating shafts of the frame assy into the round
and oblong holes.

Warning : Take care not to be injured by the blades of the cutter assy and
the half cutter assy.

(3) Insert the two locating shafts of the frame assy into the round and oblong
holes in the half spacer.

(4) After inserting the half rock pin of the half cutter assy into the groove in the
half rock gear, insert the two locating shafts of the frame assy into the round
and oblong holes.

(5) After setting the eject cam of the eject unit assy on the cutter rock pin, insert
the two locating shafts of the frame assy into the round and oblong holes.

(6) While pressing the vicinity of the screws to be tightened on each of the above
four units, tighten the two screws.

Cutter assy
(Full cutter assy)

Locating shafts

Half spacer

Half cutter assy

Mechanical unit

Eject unit assy
Two screws

Cutter rock pin

Cutter rock pin

Fig. 2.2-43 Reassembly of the Cutter Assy, the Half Spacer,
the Half Cutter Assy, and the Eject Unit Assy

II -34

[5] Reassembly of the Body Cover

(1 ) Set the cover lock actuator on the hole in the body cover diagonally from
the top. Check that the resin spring of the cover lock actuator is securely
set in the body cover.

Body cover

Resin spring of the cover lock actuator

Cover lock actuator

Body cover

Fig. 2.2-44 Reassembly of the Cover Lock Actuator

(2) Press-fit the cover lock spring on the projection on the back of the cover
lock button while slightly rotating the cover lock spring.

(3) Align the cover lock spring set in the cover lock button on the projection of
the body cover for the cover lock spring to set the cover lock button in the
body cover.

Check that the cover lock actuator slides smoothly by pressing the cover
lock button.

Body cover

Cover lock spring

Cover lock button

Fig. 2.2-45 Reassembly of the Cover Lock Spring and Button

II -35

(4) Turn the body cover over, and set the cut feed button on the projection
and hole "B" in the body cover.

(5) Insert the projection on the power supply switch button into the guide of
the power supply actuator. With the three projections set, set this button
on the projection and hole "A" in the body cover.

(6) Set the hole and the slit of the sub PCB assy on the projections of the
body cover, and tighten the two screws. At this time, check if the solder of
the harness has peeled off.

Two screws

Projection
Body cover

Power supply switch button
(ON/OFF key)

Power supply actuator

Projection

Cut feed button (FEED/CUT key)

Fig. 2.2-46 Reassembly of the Button and the Sub PCB Assy

(7) Set the sensor PCB assy on the two hooks of the body cover and press
the sensor PCB until these hooks click. (There is no screw to be
tightened.) Check if the solder of the harness has peeled off.

(8) Insert the tape end sensor assy into the square hole in the body cover,
and tighten the two screws.

Insert the tape end sensor harness into the groove in the body cover.

Two screws
Body cover

Tape end sensor assy

Hook
Sensor PCB assy

Groove in the body cover

Hook

Fig. 2.2-47 Reassembly of the Sensor PCB Assy and the Tape End Sensor Assy

11-36

PT799007

(9) Set the cover open spring on the cover open cam. While rotating the cover
open spring, set the shorter of its hooks on the hook of the cover open cam.

(1 0) Apply the specified grease (3 mm 3 ) on the cassette cover bracket and set the
damper rubber on the shaft on the side of the cassette cover bracket.
(Specified grease: Silicone grease G501)

(1 1 ) Apply the specified grease (1 mm 3 ) on the damper rubber, then set the assy
of the cover open cam and the cover open spring on the shaft of the cassette
cover bracket in the manner the damper rubber is sandwiched between the
assy and the bracket. (Specified grease: Silicone grease G501)

Apply the grease on the back

Cassette cover bracket

Damper rubber

Cover open cam

Cover open spring
Fig. 2.2-48 Reassembly of the Cover Open Cam

(12) Align the two locating projections on the body cover with the holes in the
cassette cover bracket to set the cassette cover bracket on the body cover.
At this time, check that the longer of the hooks of the cover open spring is set
on the projection on the body cover. Subsequently, tighten the two screws.

Cassette cover bracket

Cover open spring

Body cover

Locating projections

Two screws

Body cover

Cassette cover bracket
Fig. 2.2-49 Reassembly of the Cassette Cover Bracket

II -37

[6] Reassembly of the Mechanical Printing Unit and the Main PCB assy

(1 ) Set the mechanical printing unit vertically on the three locating projections
on the body cover. At this time, take care not to sandwich the harnesses
and connectors inbetween.

Set shield plate A on the two projections on the body cover.

Subsequently, tighten the two screws.

Two screws

Mechanical printing unit

Shield plate A

Body cover

Fig. 2.2-50 Reassembly of the Mechanical Printing Unit

II -38

(2) Keep the ends of the harnesses, and the connectors out of the main PCB
assy. While tilting the main PCB assy, plug the l/F connector into the
square hole at the bottom of the body cover, and then set the main PCB
on the two projections on the body cover, with shield plate A sandwiched
inbetween. Subsequently, tighten the three screws.

Three screws

Mechanical printing unit

Main PCB assy

Shield plate A

Body cover
Fig. 2.2-51 Reassembly of the Main PCB Assy

(3) Attach the head flexible cable on the back of the main frame with a tape.

Main frame

Secu

Head flexible cable

Fig. 2.2-52 Attaching the Head Flexible Cable with Tape

II -39

PT99007

(4) Set the following connectors and cables.

Note: Unlock the connector before inserting the head flexible cable, and
then lock the connector after inserting the cable. (Insert the correct
end of the cable.)

Note: If the thermal head is replaced, change the soldering point on the
main PCB meeting the resistance value of the new thermal head.

Thermal Head Resistance Values and Soldering Points

Thermal head resistance value

L

A

B

C

D

E

F

S

Soldering point

A

A

B

C

D

E

F

F

Connector to be locked

Half cutter sensor connector (P8)

Sensor PCB harness (P3)
Sub PCB harness (P2)
Head flexible cable (P9)

Full cutter sensor connector (P7)
Tape feed motor connector (P10)

Body cover

Main PCB assy

Fig. 2.2-53 Setting the Connectors and Cables

Main PCB Assy

Head flexible cable

Resistance value

7 digits

o

Jffi]

Soldering point

o

Fig. 2.2-53A Changing the Soldering Point

II -40

[7] Reassembly of the Power Supply PCB Assy

PT99007

(1 ) After orienting the inlet assy correctly in the inlet bracket, tighten the two
screws.

Note: Always mount the inlet assy in the inlet bracket in the direction
shown in the illustration below.

Inlet bracket

Inlet assy

Two screws

Fig. 2.2-54 Reassembly of the Inlet Assy

(2) Turn the bottom cover over, and set the oblong hole in shield plate B on
the projection on the bottom cover to set shield plate B on the bottom
cover.

(3) After plugging the inlet assy and power supply harnesses into the
connectors on the power supply PCB, set the power supply PCB assy on
the bottom cover, with shield plate B sandwiched inbetween. Then,
tighten the two screws.

Inlet harness

Two screws
Power supply harness

Power supply PCB assy

Shield plate B
Bottom cover

Fig. 2.2-55 Reassembly of the Shield Plate B and the Power Supply PCB Assy

11-41

PT99007

(4) Set the inlet bracket on the right and left projections on the bottom cover, and
tighten the two screws.

Two screws

Bottom cover

Inlet unit
Fig. 2.2-56 Reassembly of the Inlet Unit

(5) Pass the power supply harness through the hole in the bottom cover, and
secure it on the hook of the bottom cover.

Bottom cover

Power supply harness

Fig. 2.2-57 Securing the Power Supply Harness

11-42

PT99007

(6) Store the two large and small cores in the storage space in the bottom cover,
and insert the two harnesses (blue and brown) into the slits in the inlet
bracket.

Body cover

Fig. 2.2-58 Running the Inlet Unit Harnesses

11-43

[8] Reassembly of the Covers

PT99007

(1 ) Turn the body cover. After setting the front cover on the two ribs of the
body cover, set the front cover on the hook.

Mechanical printing unit

Body cover

Fig. 2.2-59 Reassembly of the Front Cover

(2) Insert the power supply harness into the connector on the main PCB.

Bottom cover

Power supply harness

Main PCB

Fig. 2.2-60 Connecting the Power Supply Harness and Connector

II -44

PT99007

(3) Place the bottom cover on the body cover and the front cover to reassemble
them.

Press the bottom cover against the body cover vertically and horizontally until
the four hooks inside the body cover click.

(4) Tighten screws "C" and "D" securing the bottom cover.

Pull out the (large) core from the storage space, and tighten screw "E".

Core

Screw "E

Screw "E"

Body cover

Body cover

Fig. 2.2-61 Reassembly of the Body Cover and the Bottom Cover

(5) Tighten screws "A" and "B" to secure shield plate B and the ground wire on
the half frame.

nd wire

Shield plate B

Half frame

Fig. 2.2-62 Tightening the Screw to Secure the Ground Wire

II -45

PT99007

(6) Set the lower cover on the bottom cover, and tighten the screw.

Screw

Lower cover

Bottom cover

Fig. 2.2-63 Reassembly of the Lower cover

11-46

[9] Reassembly of the Cassette Cover Components

PT99007

(1 ) Set the cover lock spring on the projection on the cover lock actuator, and
insert it until it locks into the guide of the cassette cover. After inserting it,
check that the cover lock actuator operates smoothly by pressing its end.

Cover lock actuator

Cassette cover
Fig. 2.2-64 Reassembly of the Cover Lock Actuator

(2) Press-fit the cassette spring on the projection on the back of the cassette
presser while slightly rotating the cassette spring.

(3) Set the cassette presser. At this time, check that the cassette spring is set
on the projection on the cassette cover by viewing it from the side.

After setting it, check that the three hooks are securely locked and that the
cassette presser operates smoothly.

Cassette presser

Cassette spring

Cassette presser

Cassette cover

Fig. 2.2-65 Reassembly of the Cassette Presser

II -47

[10] Reassembly of the Cassette Cover

PT99007

(1 ) While pressing the two projections on the cassette cover bracket to the
outside, insert the two projections on the cassette cover bracket into the
holes on both sides of the cassette cover.

Check that the cover open cam is engaged with the right projection on the
cassette cover.

(2) Check that the cassette cover opens and closes properly.

Cover open cam

Cassette cover

Cassette cover

Projections on the cassette
cover bracket

Body cover

Fig. 2.2-66 Reassembly of the Cassette Cover

[11] Reassembly of the Tape Cassette

Press the cover open button (cover lock button) to open the cassette cover.
Set the tape cassette from the top, and then close the cassette cover.

Tape cassette

Cover open button
(Cover lock button)

Cassette cover

Fig. 2.2-67 Reassembly of the Tape Cassette

II -48

[12] Test Printing and Operation Check

(1 ) Plug the AC cord into the machine.

PT99007

(2) With the ON/OFF (6) key held pressed, press the FEED/CUT (X) key
twice to perform test printing.

(3) During test printing, check if the tape is fed correctly for printing, and if it is
cut correctly.

If any problem is found, refer to CHAPTER IV TROUBLESHOOTING.

(4) Check that opening the cassette cover releases the roller holder assy from
the thermal head, and that closing the cassette cover crimps the roller
holder assy on the thermal head.

(5) Check that the FEED/CUT (X) key operates correctly.

(6) Check that the ON/OFF (6) key operates correctly.
• LED (ON/OFF key) Display

State of the LED Display

Lights up in green.

Data reception standby mode.

Blinks in green.

Data has been received.

Lights up in orange.

No cassette is present in the data reception standby mode.

The cover is open while data is being received (before printing).

Blinks in orange.

The cover is open in the data reception standby mode.

Blinks in red.

No cassette is present during printing.

Tape end.

Replace the cassette.

The cover is open during printing.

Communications error.

Buffer error.

Lights up in red.

Cutter jam (before and during printing, and when power is turned on).

EEPROM error.

RAM error.

II -49

CHAPTER III

ELECTRONICS

CONTENTS

CHAPTER III ELECTRONICS

3.1 CONFIGURATION OF THE ELECTRONIC PART 111-1

3.1.1 Main PCB 111-1

3.1.2 Power Supply PCB 111-1

3.1.3 Cassette Sensor PCB (Sensor PCB) III-2

3.1.4 Tape End Sensor PCB III-2

3.1.5 Switch and LED PCB (Sub PCB) III-2

3.1.6 Full Cutter Sensor III-2

3.1.7 Half Cutter Sensor III-2

3.1.8 Full Cutter Motor III-2

3.1.9 Half Cutter Motor III-2

3.1.10 Tape Feed Motor III-2

3.1.11 Thermal Head III-2

3.2 MAIN PCB III-3

3.2.1 Logic Components III-4

[1] CPU (M30622M8) III-4

[2] RAM (SRAM) III-4

[3] ROM(EEPROM) III-4

3.2.2 Solder Points III-4

3.2.3 Logic and VH Power, and Related Circuits III-5

3.2.4 Stepping Motor (Tape Feed Motor) Drive Circuit III-5

3.2.5 DC Motor (Cutter Motor) Drive Circuit III-7

[1] Full Cutter Motor Drive Circuit and Full Cutter Sensor Circuit III-8

[2] Half Cutter Motor Drive Circuit and Half Cutter Sensor Circuit III-8

[3] Process of Full or Half Cutter Errors III-9

3.2.6 Cassette Detection Sensor Circuit III-9

3.2.7 Thermal Head Control Circuit 111-10

[1] Basic Energizing Time 111-1

[2] Log Control 111-1

[3] 4-Dot Control 111-1

[4] Control by Ribbon Type 111-1

[5] Control by the Resistance Level of the Thermal Head 111-1

[6] Temperature Control 1 11-1

3.2.8 Head Temperature Detection Circuit 111-12

3.2.9 Oscillation Circuit 111-12

3.2.10 Interface Circuit 111-13

3.2.11 Tape End Sensor Circuit 111-14

3.2.12 Switch and LED Circuit 111-14

3.2.13 Cover Open Sensor Circuit 111-15

3.3 POWER SUPPLY PCB 111-15

3.1

CONFIGURATION OF THE ELECTRONIC PART

Fig. 3.1-1 shows the configuration of the electronic part.
The electronic part consists of the following components.

Power
supply
PCB

Inlet

Commercially

available

power

Half cutter Full cutter Tape end
motor motor sensor

O O O

□ □ □

P6 P5 P4

Main PCB

^D

rr>

P fl

P3D

Thermal head

O

C

Switch and LED PCB
(Sub PCB)

Cassette sensor PCB
(Sensor PCB)

^ Lr = l — I Half cutter sensor
O |_F=I — J Full cutter sensor

Tape feed motor

Fig. 3.1-1 Configuration of the Electronic Part

3.1.1 Main PCB

The main PCB controls all electronic operations.

This PCB consists of the CPU, the RAM, the EEPROM, the l/F driver, and the motor
driver.

3.1 .2 Power Supply PCB

There are two types of power supply PCB (1 00 V system for North America, and
200V system for Europe). This PCB, equipped with a switching regulator, stabilizes
commercially available power (AC voltage) to generate DC voltage. The following
two voltages are output.

VH:24VDC±0.3V
Vcc: 5V DC±0.25V

3.1.3 Cassette Sensor PCB (Sensor PCB)

The cassette sensor PCB (sensor PCB) is equipped with the sensor which detects
the cassette tape width and ink ribbon type, and the sensor (mechanical switch)
which detects the open cassette cover.

3.1.4 Tape End Sensor PCB

The tape end sensor uses a photo-interrupter to detect the tape end (zebra) pattern.

3.1 .5 Switch and LED PCB (Sub PCB)

The switch and LED PCB (sub PCB) is equipped with the ON/OFF and FEED/CUT
switches, and the LED (green/red).

3.1 .6 Full Cutter Sensor

The full cutter sensor is a sensor (mechanical switch) which detects the position of
the full cutter.

3.1 .7 Half Cutter Sensor

The half cutter sensor is a sensor (mechanical switch) which detects the position of
the half cutter.

3.1.8 Full Cutter Motor

The full cutter motor is the drive to cut the tape. This DC motor runs at a drive
voltage of VH (24V).

3.1.9 Half Cutter Motor

The half cutter motor is the drive for the half cutting of laminated tapes. This DC
motor runs at a drive voltage of VH (24V).

3.1.10 Tape Feed Motor

The tape feed motor is the drive to feed both the ribbon and the tape. This 025
stepping motor runs at a drive voltage of VH (24V).

3.1.11 Thermal Head

The thermal head has 384 dotsxl dot (360 dpi), thin-film configuration and
incorporates a drive circuit. The drive voltage is 24V.

3.2 MAIN PCB

Fig. 3.2-1 shows the main PCB block diagram.

The main PCB consists of the following components.

(1
(2
(3
(4
(5

(6

(7
(8
(9

CPU (including the ROM and the RAM)

SRAM (256 Kbytes)

EEPROM (1 Kbits)

Power supply, head power supply, FEED key, and LED ON/OFF circuits

Full cutter motor drive circuit, half cutter motor drive circuit, and tape feed
motor drive circuit

Cassette sensor circuit, cover open sensor circuit, automatic full and half cutter
sensor circuit, and tape end sensor circuit

Head level detection circuit

Ambient temperature detection circuit and head temperature detection circuit

Reset circuit

(10) RS-232C serial interface circuit

Head voltage
detection circuit

Thermal head

128 Kbytes x 2
SRAM

Reset circuit

Power supply
ON/OFF circuit

FEED key ON/OFF circuit

RS-232C serial interface

LED ON/OFF circuit

1 — VH power ON/OFF circuit

ED

1 Kbits
EEPROM

CPU

#5

M30622M8

Internal ROM

64 Kbytes

RAM
4 Kbytes

Full cutter

motor
drive circuit

Half cutter

motor
drive circuit

Tape feed

motor
drive circuit

Cassette sensor

Cover open sensor

Half cutter sensor

Full cutter sensor

Tape end sensor

Head level
detection circuit

Ambient temperature
detection circuit

DC motor

DC motor

Stepping motor

Fig. 3.2-1 Main PCB Block Diagram

3.2.1 Logic Components

[1] CPU (M30622M8)

The CPU (#5) is a 16-bit microprocessor manufactured by Mitsubishi Electric
Corp., which controls and manages the entire system.

This CPU has a 64-Kbyte internal ROM which stores all programs. The
internal RAM has 4 Kbytes.

[2] RAM (SRAM)

Two 128-Kbyte SRAMs (#1 and #2) are used as a data buffer.

[3] ROM(EEPROM)

A 1 -Kbit EEPROM (#4) is used, into which baud rate and mechanical
information is written to be stored.

3.2.2 Solder Points

Fig. 3.2-2 shows the solder point circuit.

One of solder points A-F is soldered according to the resistance level of the thermal
head.

The solder points are read once immediately after the power is turned on.

R6 RA2
1 00 K 1 00Kx4

CPU

#5

M30622M8

P72
P73
P74
P75
P76
P77

'6 N fa <& & ^ fa

(Head level) Y Y Y Y

D 1 1 S S 3 5 5 Solder points ' ' ' '

Kl

Fig. 3.2-2 Solder Point Circuit

3.2.3 Logic and VH Power, and Related Circuits

Power from a commercially available wall outlet is Vcc (+5V±0.25V) which is
supplied to the main PCB, and then to all logic components.

When Vcc is supplied, the reset IC (Q7) switches the reset signal level to high to
start the CPU.

When the CPU starts after the power is supplied, ports are initialized, and the CPU
enters the sleep state (the power is turned off).

With the power off, pressing the ON/OFF key causes the interruption of N Ml to start
the CPU, turning on the power.

With the power on, pressing the ON/OFF key places the CPU in the sleep state (the
power is turned off).

With the machine in operation, P83 is switched to high to turn on Q9 (FET),
supplying VH to the thermal head, the full cutter motor, the half cutter motor, and
the tape feed motor.

3.2.4 Stepping Motor (Tape Feed Motor) Drive Circuit

Fig. 3.2-3 shows the stepping motor drive circuit.

The 025 stepping motor is used to feed the ribbon and the tape. The stepping
motor feeds the tape 1/720 in. for one pulse (one dot for two pulses).

Drive pulses are transmitted from P1 04-P1 07 of the CPU (#5) to Q1 -Q4 to drive the
motor with a unipolar 2-2 phase excitation (AB^DA^CD^BC forward feed).

(1 ) Printing at fixed speed

The rate of fixed speed printing, at which printing is performed while the tape is
fed at a fixed speed, is 571 pps (1 .75 msec/pulse).

The through-up pulses (including pre-excitation) and through-down pulses
(including post-excitation) are 56 and 5 pulses, respectively.

(2) Halfway stop of printing

If printing is stopped halfway, the circuit continuously drives the motor (overrun
for 198 pulses) after the stop, then shuts off the power.

(3) Printing interruption (margin cutting drive, half cutting drive, and buffer full
drive)

a) At the interruption of printing, the motor overruns (five through-down
pulses) before it stops.

b) If cutter operation is necessary, full or half cutting is performed.

c) The motor rotates counterclockwise for 70 pulses.

d) The motor rotates clockwise to resume printing with 3 dots printed again.

P10
(Stepping motor)

Q4 2SD2170

CPU

P ' 07 *c

P t 6 » O

P 1 5

P ' 04 M30622M8

Fig. 3.2-3 Stepping Motor Drive Circuit

(4) Printing at low speed

If the head temperature is 41 °C or higher during printing on laminated or non-
laminated tapes, low speed printing is performed to ensure printing quality.

The through-up pulses (including pre-excitation) and the through-down pulses
(including post-excitation) are 56 and 5 pulses, respectively.

The rate of low speed printing is 426 pps (2.35 msec/pulse).

3.2.5 DC Motor (Cutter Motor) Drive Circuit

Figs. 3.2-4 and 3.2-5 show the DC motor drive circuit and the cutter sensor circuit,
respectively.

The DC motor performs the full or half cutting of the tape. With full cutting, drive
pulses are transmitted from DCR1 and DCF1 of the CPU (#5) to BA6919FP (#6) to
drive the motor. With half cutting, drive pulses are transmitted from DCR2 and
DCF2 of the CPU (#5) to BA6919FP (#7) to drive the motor.

Table 3.2-1 shows the logic of DCR1 , DCF1 , DCR2, and DCF2.

CPU

#5

M30622M8

P87
P8B

P94
P93

1 | R27 220

#6 BA6919FP

SAVE GND Rnf

NC : I -4. 7
10-15
22-25

-C24
'1 0^
(35V) 20

#7 BA6919FP

SAVE GND

NC: 1 -4, 7
10-15
22-25

(DC full cutter)

3 L A C K )

(DC half cutter)

( BLACK)

Fig. 3.2-4 DC Motor Drive Circuit

P8
(Half cutter sensor)

I2 I — °±o >

P7
(Full cutter sensor;

U-°±<

C22 z\l z\z z\z z\:C\2
102 102

C20 C23
102 102

Fig. 3.2-5 Cutter Sensor Circuit

CPU

#5

M30622M8

State

DCF1

DCR1

DCF2

DCR2

OFF

Clockwise

1

1

Counterclockwise

1

1

Brake

1

1

1

1

Table 3.2-1 Logic of the DC Motor Control

[1] Full Cutter Motor Drive Circuit and Full Cutter Sensor Circuit

The drive sequence of the full cutter motor is shown below.

The cutter stays at the home position in the normal state. (The full cutter
sensor input level is low.)

A tape cutting drive command rotates the DC motor clockwise to cut the tape.
At this time, the sensor input level switches from low to high. When this input
level switches to low again, it indicates that the cutter has returned to the home
position after cutting the tape.

When the low level of sensor input is detected, the DC motor brake is applied.
When the sensor input level switches to high again during braking, which
indicates that the cutter has passed by the home position, the DC motor
rotates counterclockwise. When the sensor input level switches to low again,
the motor brake is applied to monitor the sensor input level.

When the sensor input level switches to high, the DC motor rotates clockwise.
When it switches to low, the motor brake is applied.

If the sensor input level is low for 100 msec with the brake applied when the
above operations are repeated, the cutter is judged as returned to the home
position, completing the operations.

If an abnormal end shifts the cutter from the home position, the DC motor
rotates counterclockwise before printing to return the cutter to the home
position (initialization).

If the cutter remains at the home position 300 msec or does not return to the
home position 1000 msec after the DC motor starts rotating clockwise, it is
processed as an error.

The DC motor does not operate with the cover open, which is detected by the
cover open sensor.

[2] Half Cutter Motor Drive Circuit and Half Cutter Sensor Circuit

The cutter stays at the home position in the normal state. (The half cutter
sensor input level is low.)

A tape half cutting drive command rotates the DC motor clockwise (for 800
msec) for the half cutting of the tape. At this time, the sensor input level
switches from low to high. Then the DC motor rotates counterclockwise.
When the sensor input level switches to low again, the motor brake is applied.

If the sensor input level is low for 1 00 msec with the brake applied, the cutter is
judged as returned to the home position, completing the operations.

If the cutter remains at the home position with the DC motor rotating clockwise
or does not return to the home position 800 msec after the DC motor starts
rotating counterclockwise, it is processed as an error.

The DC motor does not operate with the cover open, which is detected by the
cover open sensor.

3.2.6

[3] Process of Full or Half Cutter Errors

An error causes LED 1 (red) to light up to disable all operations.

Turning off the ON/OFF switch turns off the power, and the subsequent
pressing of this switch turns on the power to return the cutter to the home
position.

Cassette Detection Sensor Circuit

Fig. 3.2-6 shows the cassette detection sensor circuit.

The sensor board is mounted on the cassette side so that the board turns on the
switch of the cassette sensor which detects the ribbon type and the tape width.

Table 3.2-2 shows the combinations of the cassette.

P73

P74

P75

CPU

P76

#5

P77

M30622M8

R5 <n

I 00K5 5

1 00K 100Kx4

P3 (Cassette sensor connector)

Y Y V V

Fig. 3.2-6 Cassette Detection Sensor Circuit

Cassette type

RS10

RS11

RS12

RS13

RS14

No cassette

6 mm

Laminated

1

Non-laminated

1

1

9 mm

Laminated

1

1

1

Non-laminated

1

1

12 mm

Laminated

1

Non-laminated fabric

1

1

1

18 mm

Laminated

1

1

1

Non-laminated and YS

1

Lettering and fabric

1

1

1

1

24 mm

Laminated

1

1

1

1

Non-laminated

1

1

36 mm

Laminated

1

Table 3.2-2 Combinations of the Cassette

3.2.7 Thermal Head Control Circuit

Figs. 3.2-7 and 3.2-8 show the thermal head control circuit and the thermal head
drive timing chart, respectively.

The thermal head uses a 384-dot (360 dpi) edge head and incorporates four 96-dot
driver ICs. Serial data is transferred to the four drivers in synchronization with the
clock signal. Print data is output in synchronization with the 3.685 MHz clock (a
quarter of 14.74 MHz).

In response to the LATCH signal from P62 of t he C PU, the head driver circuit
latches the print data to synchronize it with the STB signal from P80, driving the
specified heating elements.

The method of controlling the thermal head is as follows.

C L K2
C L K 3
C L K4

^

-■- C28

* *— °RET

-Wv 1

R32
1 M
— °vc c

CLK3
C L K 4

T X

CPU

#5

T X D 1

S0UT3
S0UT4
P80

M30622M8

P62

P9 (Head connector)

Fig. 3.2-7 Thermal Head Control Circuit

DIk
CLKk

LATCH

STB

SUB1

SUB2

MAIN

Fig. 3.2-8 Thermal Head Drive Timing Chart

111-10

[1] Basic Energizing Time

The energizing time is based on SUB1+SUB2+MAIN, with MAIN being used for
chopping control.

[2] Log Control

SUB2 turns on, when the two consecutive dots before the dot to be energized
are not energized. Otherwise, SUB2 turns off.

[3] 4-Dot Control

384 dots are divided into 96 4-dot blocks. SUB1 turns on, when one or two
dots are to be energized, with the preceding dot energized. Otherwise, SUB1
turns off.

[4] Control by Ribbon Type

An energizing time appropriate for the ribbon type is set.

[5] Control by the Resistance Level of the Thermal Head

The resistance values of the thermal head are classified into levels of A-F and
read from the above-mentioned solder points to calculate an energizing time
appropriate for the resistance value.

[6] Temperature Control

The temperature detection circuit reads the head temperature during printing
based on the A/D input of the CPU to set an energizing time appropriate for
these temperatures.

11

3.2.8

Head Temperature Detection Circuit

Fig. 3.2-9 shows the head temperature detection circuit.

The head temperature detection circuit uses the thermistor on the heat radiation
plate of the thermal head to convert variations in the temperature of the head into
variations in voltage to input them into the A/D input port AN1 of the CPU.

Fig. 3.2-9 Head Temperature Detection Circuit

3.2.9 Oscillation Circuit

Fig. 3.2-10 shows the oscillation circuit.

This circuit contains a 14.74-MHz oscillator to generate an oscillation at 14.74 MHz.
The internal operations of the CPU are executed based on this clock.

CPU

#5

M30622M8

i : SI HIT
1 M 1 i (J

IT1

14. 74NH;

Fig. 3.2-10 Oscillation circuit

12

3.2.10 Interface Circuit

Fig. 3.2-1 1 shows the interface circuit.

This circuit is a 8-pin, RS-232C interface circuit for making connections to a
computer.

#3 is a RS-232C driver IC which converts logic level signals into RS-232C (+ and)
signals.

The RXD signal is a print data input signal from the computer and transmitted at a
maximum baud rate of 1 1 5.2 K.

The TXD and DTR signals are control output signals to the computer.

With the power on, P66 is switched to high to turn on Q5 (transistor) so that the
power Vcc is supplied to #3.

DT A 1 4 3 Z K

\J 1 K

RT1N144C

R3

1 K

C4 _T
1 04j_

C2 JT
1 04-£_

C2 + #3

ADM202

C 2 -

-L C5
~[" 1 04

"lei

T 1 04

CPU

#5

M30622M8

Fig. 3.2-11 Interface Circuit

P1 1 (RS-232)
MD-S8 1 00-1

DTR

TXD-

RXD-

( N C : 2 , 6 , 7 ;

13

3.2.11 Tape End Sensor Circuit

Fig. 3.2-12 shows the tape end sensor circuit.

This circuit detects the voltage of P1 02 (AN2) to detect the tape end when the zebra
tape (black/transparent) at the end of the tape passes by the photosensor.

CPU

#5

M30622M8

< <

i R1 3
? 1 OK

JRI 2

220 ? KH
<l M

v

;c

I I

C 1
1 05

|3 2

I
4

F

-C8

1 02

R9:

2 2 K'

R33

330 :

(Tape end sensor)

k^ 1

[

P"

Ql 2

RT1 N14

4 C

A V S S ±0 V

Fig. 3.2-12 Tape End Sensor Circuit

3.2.12 Switch and LED Circuit

Fig. 3.2-13 shows the switch and LED circuit.

This circuit controls the ON/OFF and FEED/CUT switches and the power supply
LED.

The LED lights up or blinks in green or red according to the state of the machine.

P2 (Key LED connector)

-°± o v

-°G R E
-OR E D

Fig. 3.2-13 Switch and LED Circuit

14

3.2.13 Cover Open Sensor Circuit

Fig. 3.2-14 shows the cover open sensor circuit.

This circuit detects the open/closed state of the cassette cover.

The sensor input level is low with the cover closed, while it is high with the cover
open.

With the cover open, all drives are disabled.

R22 R4
1 OK 5. 6K

00K-

cov°-

FEED<^

R1
5. 6K

20

I NT2

CPU
#5

M30622M8

Fig. 3.2-14 Cover Open Sensor Circuit

3.3 POWER SUPPLY PCB

Commercially available power is supplied to the power supply PCB through the
power supply cord, which is inserted into an inlet. The inlet has a total of three
wires, one of which is for grounding, and the other two are for inputting AC voltage
into the power supply PCB. The switching regulator of the power supply PCB
stabilizes the AC voltage to generate DC voltage (VH: +24V ±0.3V for the thermal
head and the DC motor, and Vcc: +5V DC±0.25V for the logic components),
supplying it to the main PCB.

15

CHAPTER IV

TROUBLESHOOTING

CONTENTS PT99007

CHAPTER IV TROUBLESHOOTING

4.1 TROUBLESHOOTING IV- 1

4.1.1 Precautions on Repairing IV-1

4.1.2 Troubleshooting Flows IV-1

[1] Printing is performed with specific dots omitted IV-1

[2] The tape cassette type is not detected correctly IV-2

[3] The LED does not light up IV-2

[4] No printing is performed IV-3

[5] The interface malfunctions IV-3

[6] The tape is not cut IV-4

[7] The tape is not fed correctly IV-5

[8] Half-cut is not possible IV-7

[9] The tape is not ejected forcibly IV-8

4.1 TROUBLESHOOTING

PT99007

4.1.1 Precautions on Repairing

(1 ) Before testing electric conductivity with a circuit tester, unplug the power supply
cord and check that power is not supplied to the machine.

(2) If a printer failure occurs, unplug the thermal head cable and wait until the
thermal head and related circuits are restored to execute normal operation.

(3) Use a specified AC adapter to supply power to the machine.

4.1.2 Troubleshooting Flows

[1] Printing is performed with specific dots omitted.

The thermal head is dirty.
Clean the thermal head.

^ Replace the roller holder assy.

The thermal head is defective.
Replace the thermal head assy.

IV -1

[2] The tape cassette type is not detected correctly.

The tape cassette type is
not identified correctly.

The CPU (#5) is defective.
Replace the main PCB assy.

NO

YES

NO

[3] The LED does not light up.

Connect the cassette
sensor cable correctly.

Replace the cassette sensor PCB
assy (sensor PCB assy).

The cassette sensor assy is defective.
Replace the cassette sensor PCB
assy (sensor PCB assy).

NO

YES

NO

The switch and LED PCB
(sub PCB) is defective.
Replace the switch and

LED PCB (sub PCB) assy.

Connect the switch and

LED PCB (sub PCB) cable correctly.

Replace the switch and
LED PCB (sub PCB) assy.

The CPU is defective.
Replace the main PCB assy.

IV -2

[4] No printing is performed.

The tape is fed correctly,
but no printing is performed.

The thermal head is defective.
Replace the thermal head assy.

NO

NO

NO

[5] The interface malfunctions.

Connect the print head cable correctly.

Any of the devices on the main PCB
is defective or improperly soldered on
the PCB.
Replace the main PCB assy.

The power supply PCB is defective.
Replace the power supply PCB assy.

The RS-232C cable is defective.
Replace the RS-232C cable.

NO

YES

Connect the RS-232C cable
correctly.

The RS-232C driver or the CPU

is defective.

Replace the main PCB assy.

IV -3

[6] The tape is not cut.

PT99007

YES

YES

Replace the cutter assy.

NO

NO

^ Replace the cutter helical gear.

^ Clean the cutter assy.

Connect the stepping motor
cable correctly.

The CPU is defective.
Replace the main PCB assy.

YES

The DC motor assy is defective.
Replace the DC motor assy.

#6 is defective.
Replace the main PCB assy.

IV -4

[7] The tape is not fed correctly.

PT99007

The tape is not
fed correctly.

Replace the tape
cassette with a new
one and perform test
printing.

The problem caused
by the defective tape
cassette has been
corrected.

Connect the motor
correctly.

Replace the motor
assy with a new one.

Replace the roller
holder assy.

Any ofQ1-Q4 is
defective.
Replace the main
PCB assy.

The CPU is defective.
3| Replace the main
PCB assy.

The problem has
been corrected.

IV -5

YES

£ Replace the roller holder assy.

NO

£ Reset the rubber correctly.

YES

r S.

The problem has been corrected.

* J

v •>

YES

YES

^ Replace the main frame assy.

YES

^ The problem has been corrected.

IV -6

[8] Half-cut is not possible.

PT99007

Replace the half-frame assy.

#7 is defective.
Replace the main PCB assy.

NO

YES

YES

NO

NO

YES

$ Use laminate tape.

£ Clean the half-cutter assy.

> Replace the half-cutter assy.

Connect the DC motor
cable correctly.

The CPU is defective.
Replace the main PCB assy.

The DC motor assy is defective.
Replace the DC motor assy.

IV -7

[9] The tape is not ejected forcibly.

PT99007

Replace the half-frame assy.

#6 is defective.
Replace the main PCB assy.

YES

$ Clean the half-cutter assy.

YES

^ Replace the cutter helical gear.

NO

$ Replace the ejection roller assy.

NO

Connect the DC motor
cable correctly.

NO

The CPU is defective.
Replace the main PCB assy.

YES

The DC motor assy is defective.
Replace the DC motor assy.

IV -8

PT99064

APPENDIX

Circuit Diagram

Main PCB

Power Supply PCB

CONTENTS PT99064

APPENDIX

Main (Control) PCB Circuit Diagram APP-1

Power Supply PCB APP-2

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PT99064

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Printed in Japan